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NB/T 33006-2013: General requirements for electric vehicle battery-pack-swap equipment
NB/T 33006-2013
ENERGY INDUSTRY STANDARD OF
THE PEOPLE’S REPUBLIC OF CHINA
ICS 29.200
K 81
File No.: 43506-2014
General requirements for electric
vehicle battery-pack-swap equipment
ISSUED ON: NOVEMBER 28, 2013
IMPLEMENTED ON: APRIL 01, 2014
Issued by: National Energy Administration
Table of Contents
Foreword ... 3
1 Scope ... 4
2 Normative references ... 4
3 Terms and definitions ... 6
4 Type and basic parameters ... 7
5 Technical requirements ... 8
6 Tests ... 17
7 Inspection rules ... 20
8 Identification, packaging, transportation and maintenance ... 21
General requirements for electric
vehicle battery-pack-swap equipment
1 Scope
This Standard specifies the type, basic parameters, technical requirements,
tests, inspection rules, identification, packaging, transportation, etc. of electric
vehicle battery-pack-swap equipment (hereinafter referred to as swap
equipment).
This Standard applies to electric vehicle battery-pack-swap equipment, as the
basis for the design, manufacture, inspection, acceptance, etc. of electric
vehicle battery-pack-swap equipment.
2 Normative references
The following referenced documents are indispensable for the application of
this document. For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any
amendments) applies.
GB/T 191 Packaging - Pictorial marking for handling of goods
GB/T 715 Hot-rolled round carbon steel bars for standard parts
GB/T 1228 High strength bolts with large hexagon head for steel structures
GB/T 1229 High strength large hexagon nuts for steel structures
GB/T 1230 High strength plain washers for steel structures
GB/T 1231 Specifications of high strength bolts with large hexagon head,
large hexagon nuts, plain washers for steel structures
GB/T 1243 Short-pitch transmission precision roller and bush chains,
attachments and associated chain sprockets
GB 2894-2008 Safety signs and guideline for the use
GB/T 3323 Radiographic examination of fusion welded joints in metallic
materials
GB/T 3766 Hydraulic fluid power - General rules relating to systems
GB/T 3811 Design rules for cranes
GB/T 4942.1 Classification of degrees of protection provided by enclosures
of rotating electrical machines (IP code)
GB 5972 Wire rope for lifting appliances - Code of practice for examination
and discard
GB/T 6417 Classification and explanation of imperfections in fusion welded
joints
GB/T 7935 Hydraulic fluid power - General requirements for hydraulic
components
GB 8903 Steel wire ropes for elevators
GB/T 8918 Steel wire ropes
GB/T 8923 Rust grades and preparation grades of steel surfaces before
application of paints and related products
GB/T 9286 Paints and varnishes - Cross cut test for films
GB/T 9799 Metallic coatings - Electroplated coatings of zinc on iron or steel
GB/T 13384 General specifications for packing of mechanical and electrical
products
GB/T 13912-1992 Metallic coatings - Hot dip galvanized coatings on
fabricated ferrous products - Specification
GB 16655 Industrial automation systems - Safety of integrated
manufacturing systems - Basic requirements
GB 17907-2010 Mechanical parking systems - General safety requirement
GB 50256 Code for construction and acceptance of electric device of crane
electrical equipment installation engineering
JB 4730-2005 Nondestructive testing of pressure equipment
JB 5319.2-1991 Railroad track stacking crane - Safety specification
JB/T 5323 High bay welded steel rack - Specifications
Circular motion of the swap equipment to move about an axis perpendicular to
the working horizontal plane.
3.8
back-forth movement
Linear motion of the swap equipment to pull the battery pack out or push it into
the power bay or battery rack of the electric vehicle.
3.9
height required for battery swapping
Height of the battery pack bottom from the ground during the battery pack
swapping process of the swap equipment.
3.10
side-swapping of battery
Battery pack swapping method when the battery pack is installed on both sides
of the vehicle body.
3.11
bottom-swapping of battery
Battery pack swapping method when the battery pack is installed at the bottom
of the vehicle body.
3.12
end-swapping of battery
Battery pack swapping method when the battery pack is installed at the front
and rear ends of the vehicle body.
4 Type and basic parameters
4.1 Type
4.1.1 According to the different installation positions of the battery pack on the
electric vehicle, the corresponding swap equipment can be divided into side-
swap equipment, end-swap equipment, bottom-swap equipment and other
swap equipment.
5.2 General requirements for swap equipment
In addition to special agreements, electric vehicle battery-pack-swap
equipment shall meet the following requirements:
a) Movements are continuous, reliable and stable; the connection of
movements is smooth:
b) Except manual equipment, the battery swapping time of commercial
vehicles’ battery pack shall not exceed 600 s, and the battery swapping
time of passenger vehicles’ battery pack shall not exceed 300 s;
c) Swap equipment shall have certain adaptability to the vehicle's stopping
position and stopping posture;
d) Swap equipment shall have certain adaptability to the installation position
error of the battery pack;
e) Fully automatic swap equipment shall have a communication interface
with the monitoring system;
f) Swap equipment shall have necessary safety measures;
g) Swap equipment shall have manual unlock function when power is off.
5.3 Manufacture
5.3.1 Mechanical structure
5.3.1.1 Manufacture of structural parts
The manufacture of structural parts of electric vehicle battery-pack-swap
equipment shall meet the following requirements:
a) The manufacture of structural parts shall comply with the provisions of
GB/T 3811 and GB/T 5323;
b) Important stress-bearing structural parts such as columns, beams, steel
frame slanted bars shall be subjected to surface rust removal treatment
before painting, and shall meet the Sa2 1/2 grade specified in GB/T 8923;
the remaining steel structural parts shall also be subjected to surface rust
removal, and shall meet the Sa2 grade or St2 grade (manual rust removal);
c) For steel structural parts that require zinc immersion and electroplating,
the surface of hot zinc immersion materials shall comply with the
provisions of 7.3 of GB/T 13912-1992, and the surface of electroplated
zinc materials shall comply with the provisions of GB/T 9799;
d) For motors used in mechanisms with M4 ~ MS work levels specified in
GB/T 3811, the insulation class may be Class B; for motors used in
mechanisms with M6 and higher work levels, the insulation class shall not
be lower than Class F (it needs to be associated with the work system).
e) The degrees of protection provided by enclosures of drive motors shall not
be less than IP34 as specified in GB/T 4942.1.
5.3.3.2 Wires and cables
The selected wires and cables shall comply with the provisions of 4.5.3 of GB
17907-2010. The ends of wires and cables shall be marked or numbered.
5.3.3.3 Meters and buttons
All instruments, buttons and operation switches shall be placed at a position
convenient for the operator to observe and operate. The purpose shall be
indicated on the front of each relevant screen and cabinet, and the components
installed inside shall be marked with the code.
5.3.3.4 Electrical devices and circuits
The selection of electrical devices and the design of circuits of electric vehicle
battery-pack-swap equipment shall meet the following requirements:
a) The spacing between electrical devices shall comply with the provisions
of GB 50256 and shall comply with the principle of convenient
maintenance.
b) The degrees of protection provided by enclosures of electrical control
boxes (cabinets) shall not be less than IP34 as specified in GB/T 4942.1.
c) The main circuit of electronic control systems shall be equipped with
protection circuits such as short circuit, over current, under voltage, over
voltage and phase loss, phase sequence.
d) The lighting circuit shall be provided with a single power switch,
independent of the main power switch.
e) The electrical insulation resistance shall comply with the provisions of
4.5.7.6 of GB 17907-2010.
f) The electrical system shall meet the following requirements:
1) Interlock between operating modes to ensure that only one operating
mode is allowed at a time;
2) Actions that cannot operate parallelly shall have an electrical interlock;
Electric vehicle battery-pack-swap equipment shall have the following basic
safety protection measures:
a) When the swap equipment suddenly loses power, each action shall have
a forced stop measure;
b) Swap equipment shall have the function of preventing the battery pack
from detaching by itself;
c) After the sudden power off and forced stop of swap equipment, there shall
be no damage to the equipment, battery pack and personnel;
d) Except manual equipment, swap equipment shall be provided with an
audible and visual warning device;
e) Except manual equipment, any action of swap equipment shall have
electrical and mechanical stroke limit protection;
f) Swap equipment shall be able to be safely interlocked between actions:
g) The electrical system shall be reliably grounded.
5.5.2 Safety signs
Electric vehicle battery-pack-swap equipment shall be provided with safety
signs:
a) Corresponding safety signs (including prohibited signs, warning signs and
prompt signs) shall be set at the obvious location of entrances and exits,
operating room, maintenance site, etc. of the swap equipment workplace,
which shall meet the requirements of GB 2894-2008;
b) There shall be an anti-shock warning sign at the obvious location of power
supply cabinets.
5.5.3 Safe use
5.5.3.1 Wheels and guide wheels running on rails shall be scrapped when one
of the following cases occurs:
a) Crack;
b) The thickness wear of rim is up to 50 % of the original thickness;
c) The thickness bending of rim is up to 20 % of the original thickness;
d) The thickness wear of tread is up to 15 % of the original thickness.
Grade 2 specified in GB/T 9286.
6 Tests
6.1 Test conditions
6.1.1 Test environmental conditions
The environmental conditions of tests shall comply with the requirements of 5.1.
6.1.2 Test equipment
The accuracy of test machines and instruments shall be in accordance with the
following deviations unless otherwise specified:
a) Mass, force, time and speed: ±1 %;
b) Voltage, resistance, current, power: ±1 %;
c) Temperature: ±2 °C:
d) Length: Select instruments and measuring tools according to the
measuring range; determine the accuracy level for mechanical
engineering measurement. For example, the measuring accuracy shall be
above Grade II when using steel tape.
Test instruments and measuring tools shall have a certificate of conformity and
a certificate of calibration during the validity period issued by a qualified
metrological verification agency.
6.2 Test contents
6.2.1 Visual inspection
It shall inspect the integrity, specifications, and/or status of important parts
(such as each mechanism, electrical equipment, safety devices, metal
structures and connectors) of swap equipment.
Visual inspection shall also include inspecting whether the necessary certificate
documents, etc. have been provided and reviewed.
6.2.2 Main dimension inspection
a) Main structural dimensions of swap equipment;
b) Dimension adapts to the battery pack.
noise; no system alarms appear.
6.3.4 Functional performance test
6.3.4.1 Battery pack swapping time test
When the electric vehicle enters the battery pack swapping position and stops,
the operator gives the instruction of starting battery pack swapping and starts
timing using the stopwatch, and the swap equipment starts swapping the
battery pack. After all the battery packs are swapped, the stopwatch is stopped.
The time taken for this process is the battery pack swapping time.
The battery pack swapping time shall meet the factory-exit performance
specifications of swap equipment and shall meet the requirements of item 5.2
b) in this document.
6.3.4.2 Noise test
Under the rated load and rated speed, when the equipment is used for lifting,
vertical and horizontal movements, use the sound level meter to measure the
noise according to the A-range reading at a distance of 1 m from the equipment
and 1.2 m from the ground. The difference between the total noise and the
background noise shall be more than 10 dB (A). The total noise measured is
the actual noise value of the equipment. Measure three times and take the
maximum value, which shall meet the requirements of 4.2.3.
6.3.4.3 Positioning accuracy test
Measure directly with a steel ruler. Under the rated load, operate the swap
equipment to the pre-designated position three times. Take the value of the
difference between the measured actual stop position and the theoretical stop
position. The test result shall comply with the provisions of 4.2.1.
6.3.4.4 Running stability test
Give an appropriate stroke, use the stopwatch to measure the time that each
moving mechanism of the swap equipment passes the given stroke at the rated
speed under the rated load, calculate the actual speed. Measure three times.
Compare with the theoretical rated speed. The maximum deviation is taken as
the test result, which shall meet the requirements of 4.2.
6.3.4.5 Power supply phase loss and phase sequence protection function
check
Power supply phase loss and phase sequence protection function check:
Disconnect any phase of the power supply or interchange the two wires of the
three-phase power supply, the equipment shall not be able to start or run.